System and method for manufacturing a tubular container with opening and closing means

ABSTRACT

According to various embodiments of the invention, systems and methods are provided for manufacturing a tubular container with a seal and release mechanism. Specifically, in accordance with one embodiment, a method for manufacturing a tubular container is provided, comprising: creating a tube having a first end and a second end, wherein the first and second ends are open; sealing the first end of the tube; scoring the tube at a predetermined location such that the tube at the predetermined position is made easier to break relative to other locations along the tube; loading the tube into a collection unit such that the second end is positioned for filling; filling the tube with a predetermined amount of a selected liquid; and filling the tube with a liquid blocker after filling the selected liquid, wherein the liquid blocker inhibits the flow of the selected liquid and seals the selected liquid inside the tube.

FIELD OF THE INVENTION

The present invention relates to containers and delivery systems. More particularly, some embodiments relate to manufacturing sealed and slender tubular containers with a seal and release mechanism.

DESCRIPTION OF THE RELATED ART

Liquid filled applicators have been in conventional use for quite some time within both medical and non-medical contexts. These applicators provide a convention method for applying the liquids they contain, require very little space for storage and transportation, and eliminate evaporation issues that may plague a conventional bottle or vial used to store liquids. A variety of liquids can be stored in and applied by such an applicator, including perfume, alcohol, detergent, and medicine. Additionally, within the context of medical applications, the applicators have the added benefit of preventing contamination of the medicine stored within, and providing controlled and measured application of the medicine.

U.S. Pat. No. 5,702,035, filed on Sep. 5, 1995 by Chien-Hua Tsao as U.S. patent application Ser. No. 08/524,386, provides a variety of example liquid filled applicators as described above, and is hereby incorporated by reference in its entirety. One example includes a liquid filled applicator having a slender tubular form and equipped with cotton swabs on one or both ends of the tube. In this example, the liquid contained within the tube is sealed and released only once the sealing element is broken. FIG. 1 (prior art) illustrates a front and cutaway view of this particular applicator.

Referring now to FIG. 1, the applicator 10 comprises a tubular container (tube) 12 having a hollow barrel, and an absorbing element (applicator) 14 at an applicator end 13. As illustrated, the absorbing element 14 in this instance is a cotton swab. Within the hollow barrel is a non-toxic, liquid blocker 22, such as a liquid silicone stopper, disposed nearest the end where the absorbing element 14 is located (the applicator end 13). Such a liquid blocker both inhibits flow of the liquid 18 and seals the liquid 18 within the hollow interior of the tube 12. A gap 24 is located between the absorbing element 14 and the blocker 22. The other (sealed) end 17 of the tube 12 is sealed with a sealing element 16. A notch 20 is formed at the connection of the sealing element 16 and the tube 12 such the notch allows the sealing element 16 to be easily broken from the tube 12 of the applicator 10.

Contained within the hollow interior of tube 12 is liquid 18. When a user wishes to apply the liquid 18 within the applicator 10, the sealing element 16 is broken at the notch 20 while holding the sealed end higher than the applicator end 13. In doing so, atmospheric pressure is allowed to flow through the break point (i.e., at the notch 20) of the seal element 16 and causes the liquid 18 to flow through the blocker 22, through the gap 24, and into the absorbing element 14. The atmospheric pressure through the broken seal causes the silicone to cling to the walls of the tube, thereby forming a throughway for the liquid 18 to flow through. Once the liquid 18 is released, the absorbing element 14 contains the liquid 18 and can applied to a target area, such as treatment of a wound. Other applications for applicator 10 include beauty care (e.g., makeup remover, skin conditioner), oral care (e.g., dental whitening), health care (e.g., acne treatment, antiseptic applicator), and general hygiene (e.g., ear cleanser).

However, conventional liquid filled applicators such as described above have not previously been manufactured using an efficient method for mass-producing liquid filled applicators that meet a specific level of quality.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

According to various embodiments of the invention, systems and methods are provided for manufacturing a tubular container with a seal and release mechanism. According to these embodiments, liquid filled applicators can be quickly and efficiently mass produced with a high level of quality.

In accordance with one embodiment, a method for manufacturing tubular container is provided, comprising: creating a tube having a first end and a second end, wherein the first and second ends are open; sealing the first end of the tube; scoring the tube at a predetermined location such that the tube at the predetermined position is made easier to break relative to other locations along the tube; loading the tube into a collection unit such that the second end is positioned for filling; filling the tube with a predetermined amount of a selected liquid; filling the tube with a liquid blocker after filling the selected liquid, wherein the liquid blocker inhibits the flow of the selected liquid and seals the selected liquid inside the tube; and centrifuging the tube to reduce or eliminate air bubbles if necessary. The tubular container that results from such an embodiment is a liquid filled container that effectively has two sealed ends—one end is sealed at the tip and the other tip is sealed by the liquid blocker. As previously noted, the liquid blocker functions both as an inhibitor to liquid flow and a seal that protects the liquid from the outside environment. Examples of liquid blocker include silicone oil, which has the added benefit of being non-toxic to humans, and a small membrane. Additionally, the liquid filled container is configured with a simple release mechanism at the location where the tube is scored.

In order to improve quality of the liquid container, the method in some embodiments further comprises extracting a portion of the selected liquid that is in excess of the predetermined amount, thereby ensuring the proper amount of liquid is contained within the sealed container. This may be especially important for liquid containers used in the medical context.

In additional embodiments, the method further comprises attaching a first applicator over the first end, a second applicator over the second end, or both. The applicator can be an absorbent material that is suitable for applying the liquid contained within the tube. For example, the applicator may be a cotton swab, a brush, or a sponge. In certain embodiments, the applicator is made of a polymer material which is soft, has high plasticity, a good absorbing capability and is resilient. Additionally, the first applicator may be attached over the first end such that the first applicator covers the predetermined location on the tube. Further, the second applicator may be attached to the second end such that the liquid can flow through the second end and be absorbed by the second applicator.

With regard to creating the tube, in some embodiments, the tube's creation involves extruding the tube from a plastic material. As such, in some such embodiments, the method further comprises curing the tube after the tube is extruded. Depending on the embodiment, the plastic material utilized may be polypropylene (PP), polyethylene (PE), polyvinyal chloride (PVC), or polystyrene (PS). Depending on the desired end product, the creation of the tube can further involve reshaping the tube, or coating the tube. Examples of coatings include, but are in no way limited to, materials for strengthening the tube and materials for protecting the tube from ultraviolet (UV) rays.

In further embodiments, the process of extruding the tube involves applying an additive to the plastic. The types of additives that can be applied are well known to those of ordinary skill in the art. Such additives typically make the plastic cleaner, tougher and safer for use. Some common examples include antistatic agents that prevent the build of static charge in the plastic, antimicrobials which make the plastic less susceptible microbiological attack, and biodegradable plasticisers which enhance the degradability of the plastic once they are disposed.

In other embodiments, the sealing operation is performed using a heating element that can seal tubes individually or in bulk. In some other embodiments, the scoring operation may be performed after the filling operations but before the operation of attaching the second applicator over the first end. Scoring operations may vary in depth and pattern from embodiment to embodiment.

With further regard to applicators, the first applicator, the second applicator or both can be attached over their respective ends by using hot melt, melting the tube on hot rails, or using cold glue. Furthermore, in some embodiments, the method further comprises applying a designator on the first applicator, thereby designating a location of the first end. This is useful for indicating to a user which end of the liquid filled applicator has the release mechanism.

Other features and aspects of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features in accordance with embodiments of the invention. The summary is not intended to limit the scope of the invention, which is defined solely by the claims attached hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention, in accordance with one or more various embodiments, is described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or example embodiments of the invention. These drawings are provided to facilitate the reader's understanding of the invention and shall not be considered limiting of the breadth, scope, or applicability of the invention. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.

FIG. 1 (prior art) is a diagram illustrating the front and cutaway view of a known applicator.

FIG. 2 is a flowchart illustrating an example method in accordance with an embodiment of the invention.

FIG. 3 is a graphical flowchart illustrating the example method in accordance with an embodiment of the invention.

FIG. 4 is a flowchart of an example production flow in accordance with an embodiment of the invention.

The figures are not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be understood that the invention can be practiced with modification and alteration, and that the invention be limited only by the claims and the equivalents thereof.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

The present invention is directed toward a system and method for manufacturing a tubular container with a seal and release mechanism. The following description is presented to enable any person skilled in the art to make and use the invention. Descriptions of specific applications, methods, and apparatus are provided only as examples. Various modifications to the preferred embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

FIG. 2 is a flowchart illustrating an example method 40 in accordance with an embodiment that produces a liquid filled container and applicator having tubular form and capable of sealing the liquid contained therein. The method 40 begins with the creation of a tube at operation 42. In some embodiments, a tube is created with a hollow cavity that is less than 6 mm in diameter. One end of the tube is sealed at operation 44. For the purposes of this description, this sealed end will be designated the first end, while the opposite end of the tube will be designated the second end.

Subsequently, the tube is scored at operation 46 at a predetermined distance from the first end. The tube is scored to such an extent that the first end can be easily broken from the tube when a user wishes to release the liquid from the liquid filled container (i.e., the tube). Accordingly, in some embodiments, the tube is scored sufficient to form a notch in the tube that enables the first end to be easily broken by applying a small force to the first end of the tube in a direction substantially normal to the length of the tube.

Next, the tube is placed into a collection unit at operation 48, such a tray, block, or rails, such that the second end of the tube is facing equipment capable of filling the tube with a liquid. As noted previously, examples of liquids include perfume, alcohol, detergent, and medicine. The tube is then filled with a predetermined amount of the selected liquid at operation 50, followed by a liquid blocker at operation 52. The liquid blocker functions as both a liquid flow inhibitor and a sealant that protects the liquid contained within the tube. In some embodiments, the filling operation may be facilitated using a filling instrument configured with a needle or an injector.

In some embodiments the liquid blocker is a silicone stopper made of silicone dioxide, or the like, which is non-toxic, has proper adhesiveness, and allows liquid to flow through the blocker once the sealed end is broken. With the silicone stopper, when the first (sealed) end is not broken, the atmospheric pressure from the second (open) end causes the silicone to remain in place. However, once the sealed end is broken, the atmospheric pressure causes the silicone to cling to the walls of the tube, thereby allowing the liquid to flow through the liquid blocker.

Next, at operation 54, the tube is centrifuged to reduce air bubbles within the tube. The method then concludes with the attachment of an applicator, such as a cotton swab, to either or both ends of the tube.

FIG. 3 is a graphical flowchart illustrating an example method 90 that may be performed in conjunction with the method 40 illustrated in FIG. 2. As illustrated, the tube is 93 is extruded from a plastic resin, such as polypropylene (PP), polyethylene (PE), polyvinyal chloride (PVC), or polystyrene (PS). Once the tube 93 is sealed at end 98 and scored at location 100, it is filled with a liquid 98 via a needle 95 through the open end 96 of the tube. This is followed by filling or depositing a liquid blocker 97 over the liquid 98, thereby inhibiting the liquid 98's movement and sealing liquid 98 inside the tube 93. The method 90 concludes with a tipping process, where cotton swab applicators 102 and 104 are attached to the tube 93.

Referring now to FIG. 4, a flowchart is provided of an example production flow 120 in accordance with an embodiment of the invention. Before describing the production flow 120, it should be noted that throughout the production flow 120, various sample tests and inspections are performed at specific points in the flow to ensure that products of an acceptable quality are produced. For example, some of the operations performed include various sample tests (124, 160), various online inspections (128, 142, 146, 152), an inspection of the solution and oil filled in tube (134), and an acceptable quality limit (AQL) inspection (138).

The production flow 120 begins with the manufacturing of a plastic resin at operation 122, which is used to create tubes during the extrusion process of tubing operation 126. In some embodiments, the tube can also be colored during the extrusion process using additives. During the tubing operation 126, the tube is sealed on one end and scored at a predetermined distance from the sealed end. Optionally, the scoring process can be performed during the tipping process (operation 140).

The tube is subsequently sorted at operation 130, and filled with the solution (i.e., the selected liquid) and silicone oil (i.e., the liquid blocker) at operation 132. This is followed by the centrifuging operation 136, which, as noted previously, reduces the air bubbles within the liquid filled container.

At operation 140, the liquid filled container is tipped with cotton swabs as applicators. Additionally, operation 140 may involve applying starch and coloring to the cotton swab. Specifically, at operation 140, some embodiments involve placing a colored ring or marking around the cotton swab that covers the sealed end that serves as the release mechanism for the solution. Some such embodiments may use a line marking method similar to the means disclosed in U.S. Pat. No. 6,779,275, filed on Mar. 26, 2002 by Garry Tsaur as U.S. patent application Ser. No. 10/106,612, which is hereby incorporated by reference in its entirety. Following the operation 140, the liquid filled applicator has finished production.

What follows next is the packaging of the liquid filled applicator, which begins with labeling and sampling operation 144. At operation 144, samples of the liquid filled applicators are taken and the applicators are labeled to indicate their contents and intended purpose. Next, cases of the liquid filled applicators are packed into a tray or folding box at operation 148. The tray or folding box is subsequently packed in larger boxes at operation 154 before undergoing a final inspection at operation 158.

As used herein, the term set may refer to any collection of elements, whether finite or infinite. The term subset may refer to any collection of elements, wherein the elements are taken from a parent set; a subset may be the entire parent set. The term proper subset refers to a subset containing fewer elements than the parent set. The term sequence may refer to an ordered set or subset. The terms less than, less than or equal to, greater than, and greater than or equal to, may be used herein to describe the relations between various objects or members of ordered sets or sequences; these terms will be understood to refer to any appropriate ordering relation applicable to the objects being ordered.

While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not of limitation. Likewise, the various diagrams may depict an example architectural or other configuration for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated example architectures or configurations, but the desired features can be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations can be implemented to implement the desired features of the present invention. Also, a multitude of different constituent module names other than those depicted herein can be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.

Although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.

Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration. 

1. A method for manufacturing a tubular container, comprising: creating a tube having a first end and a second end, wherein the first and second ends are open; sealing the first end of the tube; scoring the tube at a predetermined location such that the tube at the predetermined position is made easier to break relative to other locations along the tube; loading the tube into a collection unit such that the second end is positioned for filling; filling the tube with a predetermined amount of a selected liquid; filling the tube with a liquid blocker after filling the selected liquid, wherein the liquid blocker inhibits the flow of the selected liquid and seals the selected liquid inside the tube; and centrifuging the tube to reduce air bubbles.
 2. The method of claim 1, further comprising attaching a first applicator over the first end.
 3. The method of claim 2, wherein the first applicator is attached over the first end such that the first applicator covers the predetermined location on the tube.
 4. The method of claim 1, further comprising attaching a second applicator over the second end, such that the liquid can flow through the second end and be absorbed by the second applicator.
 5. The method of claim 2, wherein the first applicator is a cotton swab, a brush, or a sponge.
 6. The method of claim 4, wherein the second applicator is a cotton swab, a brush, or a sponge.
 7. The method of claim 1, wherein creating the tube involves extruding the tube from a plastic material.
 8. The method of claim 7, wherein the plastic material is polypropylene, polyethylene, polyvinyal chloride, or polystyrene.
 9. The method of claim 7, further comprising curing the tube after the tube is extruded.
 10. The method of claim 7, wherein extruding the tube involves applying an additive to the plastic.
 11. The method of claim 1, wherein creating the tube involves reshaping the tube.
 12. The method of claim 1, wherein creating the tube involves coating the tube.
 13. The method of claim 1, further comprising extracting a portion of the selected liquid that is in excess of the predetermined amount.
 14. The method of claim 1, wherein the liquid blocker is silicon oil or a membrane.
 15. The method of claim 1, wherein the sealing operation is performed using a heating element.
 16. The method of claim 3, wherein the scoring operation is performed after the filling operations but before the operation of attaching the second applicator over the first end.
 17. The method of claim 2, wherein the first applicator is attached over the first end by using hot melt, melting the tube on hot rails, or using cold glue.
 18. The method of claim 4, wherein the second applicator is attached over the second end by using hot melt, melting the tube on hot rails, or using cold glue.
 19. The method of claim 2, further comprising applying a designator on the first applicator, thereby designating a location of the first end. 